Method of forming a pile fabric



Jan. 25, 1966 N, wlGNALL ETAL 3,230,917

METHOD OF FORMING A PILE FABRIC Filed Dec. 5, -1962 5 Sheets-Sheet 1 w INVENTOR: NoaMHN gNALL Y Tohu 'RbAKb BY el w Jan. 25, 1966 N. wlGNALL ET AL 3,230,917

METHOD OF FORMING A PILE FABRIC Filed Deo. 3, 1962 5 Sheets-Sheet 2 ...111111111111llllalllllllllllmllul.r11/nr.

NORMAN WNW au- Tung Kim/mlb INVENTOR:

Jan. 25, 1966 N. wlGNALL ETAL 3,230,917

METHOD OF FORMING A PILE FABRIC 5 Sheets-Sheet 5 Filed Dec. 5. 1962 INVE NTORZ CN MW BY United States Patent O 3,230,917 METHD F FORMING A IlLE FABRIC Norman Wiguall, Blackburn, John Ridyard, Bradshaw, near Bolton, and James Barrie Higham, Blackburn, England, assignors to` Kiutslaid Engineering Company Limited, Chorley, England, a company of Great Britain and Northern Ireland Filed Dec. 3, 1962, Ser. No. 241,782 Claims priority, application Great Britain, Feb. 23, 1962, 7,092/62; June 2, 1962, 21,355/62 8 Claims. (Cl. 112--266) This invention concerns a method of producingA tufted fabrics.

Throughout this specification the term plain-needle is used to indicate a standard needle of a type having a closed eye, through which yarn or other filaments may be led. The term compound-needle is used to mean a needle of the type having an open eye or hook, which can by closed by means of a latch which is adapted to pivot from a first position wherein the hook is closed, to a second position wherein the hook is open.

According to the invention a method `of forming pile loops on a base fabric in order to produce a fabric having tufted pile includes the steps of projecting a thread or the like through said base fabric successively at spaced intervals by means of a reciprocating plain-needle, forming a loop on the face of said base fabric opposite the place of entry of said plane-needle through said base fabric by co-operation of a compound needle with said plain-needle and said thread or the like, reciprocating and controlling said compound needle in such a manner as to draw alternate loops which are to form pile loops through the preceding loops which are to form locking loops, tensioning said thread or the like in such a manner as to pull said preceding loops tight around said pile loops.

According to a preferred feature of the invention the method aforesaid includes the further step of providing a reciprocating looper adapted to co-operate with said plain-needle and said thread or the like to form pile loops which bridge alternate spaces between :adjacent positions of penetration of said plain-needle on the face of said base fabricv through which said plain-needle enters.

According to one feature of the invention said looper is operative between each penetration of said plain-needle responsible for forming -a pile loop and the following penetration.

According to an alternative feature of the invention said looper is operative between each penetration of said plain-needle responsible for forming a locking loop, and the following penetration.

Also according to the invention is a machine for carrying out any one of the methods aforesaid.

Also according to the invention is a fabric produced by any one of the methods aforesaid.

These, and further features of the invention will be apparent from the following description with reference to the accompanying drawings, which show, by way of example, only, one form of machine for carrying out the method according to the invention, and a number of stitch formations produced thereby.

Of the drawings:

FIG. 1 shows a section through the machine in the line of movement 4of the backing cloth;

FIGS. 2 to 10 inclusive show the consecutive stages of a cycle of operation of the machine to produce a completed stitch formation on the backing cloth;

FIG. 11` shows an enlarged view of the stitch formation;

FIG. 12 shows `an enlarged view of an alternative form of stitch formation; and

3,230,917 Patented Jan. 25, 1966 "ice FIG. 13 shows an enlarged view of a still further form of stitch formation.

Referring now to FIG. 1 of the drawings; the machine includes a pair of rollers 10 and 11, which are adapted to pass (in the direction of the arrow) a sheet of backing cloth C, step-wise longitudinally through the machine and under a multiplicity of plain-needles arranged in a row transversely of the cloth C. One such needle is shown on FIG. l, and is designated bythe reference numeral 12'. Each needle 12 is fed with yarn Y which passes through a compound mechanism generally indicated by the reference numeral 13. The needles 12 are adapted to move in a reciprocating fashion in synchronisation with the stepwise movement of the backing cloth C, and each needle is adapted to penetrate the backing cloth C on its downand a compound needle, generally designated by the refer-V ence numeral. 16. Each compound needle 16 consists essentially of a hook like formation 17 carried on the end of al shank 18 whichhas a slot therethrough, in which is pivoted a latch 19, whose upper end protrudes above the upper surface of the shank 18. The upper end of the latch 19 is adapted to co-operate with a latch controller 20, and is adapted to be moved thereby from a position wherein the latch 19 closed the hook formation- 17 toI form an eye to a generally dependent position wherein the hook formation 17 is open.

The various parts 12, 13, 15, 18 and 20 are controlled by a mechanical arrangement of known kind whereby the various parts co-operate with one another to execute a cycle of operations in which they move in timed sequence with one another as will now be described.

For convenience, the operation of one needle 12, and its associated parts only is described, and it will be appreciated that all the needles 12 and their associated parts behave in a like manner.

Referring now to FIG. 2, at the commencement of operations the needle 12 begins to move downwardly to penetrate the backing cloth C, the compound needle 16 begins to move forward to pick up a loop, .and the latch controller 20 begins to move forwardly to open the latch, thus ensuring a clean pick olf from the needle 12.

Referring now to FIG. 3, it will be seen that the needle 12 has pierced the backing cloth C, and that the compound needle 1'6 has advanced and passed between the needle 12 and the yarn Y. The latch controller 20 has advanced to a position just clear of the needle 12, and it remains in this position whilst the compound needle 16 advances untill the yarn-Y is placed behind the latch 19.

Referring now to FIG. 4, it will be seen that the needle 12 has begun to rise, the compound needle 16 begins to move back, and the latch 19 comes into contact with the latch controller 20, which prevents the latch 19 fromI closing, which thus holds the loop so formed on the cornpound needle 16. The compound needle 16 and the latch controller 20 move to their back positions together and at a uniform rate, so that the loop is held on the compound needle 16.

Referring now to FIG. 5, it will be seen that the backing4 cloth C has advanced by one step, and that the needle 12 has descended to penetrate the backing cloth C at a position spaced from the previous penetration. The compound needle 16 and latch controller 20 have moved forward' together, so that the compound needle' 16has` passed between the yarn Y andthe needle 12, thus taking a second loop which is placed in front of the latch 19', in the hook formation 17.

Referring now to FIG. 6, it will be seen that the needle 12 has begun to rise, and that the latch needle has two loops thereon, which are held in separation by the latch 19, which is held in its dependent position, wherein the hook formation 17 is open, by the latch controller 20.

Referring now to FIG. 7, it Will be seen that the needle 12 is still rising, and that the compound needle 16 and latch controller 17 have moved back, but that the latch controller 20 has moved back further than the compound needle 16, thus allowing the latch 19 to close, with the result that the rst formed loop has been thrown off the compound needle 16 over the second formed loop. At this stage the compounding mechanism 13 is operated to pull the yarn back, causing the first loop to be pulled tight around the second loop. During this part of the cycle, the top looper 15 begins to move back ready for its operation.

Referring now to FIG. 8, it will be seen that the needle 12 has reached its top position, and that the compound needle 16 has moved forward with the result that the second loop has slid behind the latch 19, the latch controller 20 having remained in its back position. At this stage the top looper 15 has reached its back position.

Referring now to FIG. 9, it will be seen that the backing cloth C has advanced by a further step and that the needle 12 has begun to descend again. The compound needle 16 has moved back, and since the latch controller 20 has been clear of the latch 19, the loop has been cast off to form a pile loop. The top looper 15 has moved forwardly and passed between the needle 12 and the yarn Y.

Referring now to FIG. 10, it will be seen that the needle 12 has penetrated the backing cloth C, and that the yarn Y has been placed over the top looper 15, to form a pile loop on the top face of the backing cloth C, the tension in the yarn Y has caused the previous pile loop on the lower face of the backing cloth C to reduce slightly to its correct pile height, so that as the backing cloth C advances further, the pile loops on the lower face thereof will override the compound needle 16 and latch controller 20. The operational cycle now continues from the stage illustrated in FIG. 3.

Referring now to FIG. 11, the stitch formation produced by the operations described above is shown. It will be seen that the backing cloth C is provided with a loop pile on both faces thereof. It will also be seen how alternate loops which form the loop pile have been drawn through the preceding loops, which have been pulled tight therearound to form locking loops. The pile loops on the upper face of the backing cloth C have been formed by the operation of the top looper 15, which has been in operation between each penetration of the needle 12 responsible for forming a pile loop on the lower face of the backing cloth C, and the following penetration of the needle 12.

The machine may be operated in a different manner, wherein the top looper 15 is operated between each penetration of the needle 12 responsible for forming a locking loop on the lower face of the backing cloth C, and the following penetration, in which case the stitch formation is modified, and is as shown in FIG. 12.

Furthermore, if the machine described above is operated with the top looper 15 held continuously in an inoperative retracted position, a fabric, which is tufted on one face only, may be produced. If it is desired to produce a fabric tufted on one face only, the machine need not be provided with a top looper, or alternatively, if it is so provided, the top looper 15 is held continuously in an inoperative retracted position, and the machine is operated and the parts 10, 11, 12, 13, 16, 17, 18, 19 and 20 are actuated exactly as described hereinbefore to produce the stitch formation shown in FIG. 13, which is identical to those shown in FIGS. 1l and 12 except for the omission of the pile loops on the upper face of the base fabric,

which are not formed due to the omission or inoperative condition of the top looper.

It will be appreciated that due to the multiplicity of needles 12 and their associated parts in the machine, the backing cloth C is provided with pile loops on one or both faces thereof, which loops are arranged in closely adjacent longitudinally extending rows thereon.

The invention is applicable to all kinds of tufted fabrics, including carpets, towelling, velvets, chenilles and so forth.

It produces a fabric tufted on one or both sides, and with the tufts firmly secured in position.

It will be appreciated that it is not intended to limit the scope of the invention to the above examples only, many variations being possible, such as might occur to one skilled in the art, without departing from the principles of the invention.

Thus, for example, the machine for producing the stitch of the invention may be different, and it may have compound needles of a different construction, such as for example a conventional latch looper. The machine need not have a multiplicity of needles and their associated equipment, one such needle and its associated equipment being possible for the production of a decorative pile on a piece of fabric.

What we claim is:

1. A method of forming pile loops on a base fabric in order to produce a fabric having a tufted pile, including the step of repeatedly effecting the cycle consisting of projecting yarn through. said base fabric by means of a reciprocating plain needle, advancing a compound or latched needle disposed on the opposite side of said base fabric from that through which said plain needle enters and retracting said plain needle in such a manner that a loop of yarn is formed directly upon the shank of said compound needle and held on the shank of said compound needle behind the latch thereof, retracting the compound needle with said loop held thereby in its position behind said latch, advancing said base fabric and again projecting said yarn therethrough by means of said plain needle, advancing said compound needle and retracting the plain needle so that a further loop is formed and held in the hook of said compound needle, retracting said compound needle so that said second-mentioned loop is pulled through said first-mentioned loop, tensioning said yarn for tightening of the first-mentioned loop, which forms a locking loop around said second-mentioned loop, which forms a pile loop, advancing said compound needle, whereby said second-mentioned loop is passed over the latch to `lie on the shank of the compound needle, and retracting said compound needle whereby said pile loop is shed therefrom, and advancing said base fabric by a further step.

2. A method as set forth in claim 1, including the further step of holding said yarn by means of a reciprocating looper to form pile loops on the face of the base fabric through which said plain needle enters and which bridge alternate spaces between adjacent positions of penetration of said plain needle.

3. A method as set forth in claim 2, in which the step of holding said yarn by. means of a reciprocating looper is effective between each penetration of said plain needle responsible for forming a pile loop and the following penetration.

4. A method as set forth in claim 2 in which the step of holding the yarn by means of a reciprocating looper is effective between each penetration of said plain needle responsible for forming a locking loop and the following penetration.

5. A method according to claim 1 including the further steps of holding the movable element of said compound needle in its open position throughout the steps of forming said first and second-mentioned loops and releasing said movable element whereby it may close to enable the second-mentioned loop to be pulled through the first-mentioned loop.

6. A method according to claim 2 including the further steps of holding the movable element 0f sai-d compound needle in its open position throughout the steps of forming the first and second loops, and releasing said movable element whereby it may close to enable the second-mentioned loop to be pulled through the rst-mentioned loop.

7. A method according to claim 3 including the further steps of holding the movable element of said compound needle in its open position throughout the steps of forming said first and second loops and releasing said movable element whereby it may close to enable the second-mentioned loop to be pulled through the first-mentioned loop.

8. A method according to claim 4, including the further steps of holding the movable element of said compound needle in its open position throughout the steps of forming said irst and second loops, and releasing said movable element and causing it t0 close to enable the second-mentioned loop to be pulled through the first-men- 20 tioned loop.

References Cited by the Examiner UNITED STATES PATENTS Drolet 112-410 Myers 112-795 Williams 66-121 Sigoda 112--198 Pledger 68-85 Kahn 112-409 Hamrick 112--79 Lacey 112-266 Lacey 112-79 Keen 112-266 FOREIGN PATENTS JORDAN FRANKLIN, Primary Examiner.

DAVID J. WILLIAMOWSKY, Examiner. 

1. A METHOD OF FORMING PILE LOOPS ON A BASE FABRIC IN ORDER TO PRODUCE A FABRIC HAVING A TUFTED PILE, INCLUDING THE STEP OF REPEATEDLY EFFECTING THE CYCLE CONSISTING OF PROJECTING YARN THROUGH SAID BASE FABRIC BY MEANS OF A RECIPROCATING PLAIN NEEDLE, ADVANCING A COMPOUND OF LATCHED NEEDLE DISPOSED ON THE OPPOSITE SIDE OF SAID BASE FABRIC FORM THAT THROUGH WHICH SAID PLAIN NEEDLE ENTERS AND RETRACTING SAID PLAIN NEEDLE IN SUCH A MANNER THAT A LOOP OF YARN IS FORMED DIRECTLY UPON THE SHANK OF SAID COMPOUND NEEDLE AND HELD ON THE SHANK OF SAID COMPOUND NEEDLE BEHIND THE LATCH THEREOF, RETRACTING THE COMPOUND NEEDLE WITH SAID LOOP HELD THEREBY IN ITS POSITION BEHIND SAID LATCH, ADVANCING SAID BASE FABRIC AND AGAIN PROJECTING SAID YARN THERETHROUGH BY MEANS OF SAID PLAIN NEEDLE, ADVANCING SAID COMPOUND NEEDLE AND RETRACTING THE PLAIN NEEDLE SO THAT A FURTHER LOOP IS FORMED AND HELD IN THE HOOK OF SAID COMPOUND NEEDLE AND RETRACTING COMPOUND NEEDLE SO THAT SAID SECOND-MENTIONED LOOP IS PULLED THROUGH SAID FIRST-MENTIONED LOOP, TENSIONING SAID YARN FOR TIGHTENING OF THE FIRST-MENTIONED LOOP, WHICH FORMS A LOCKING LOOP ROUND SAID SECOND-MENTIONED LOOP, WHICH FORMS A PILE LOOP, ADVANCING SAID COMPOUND NEEDLE, WHEREBY SAID SECOND-MENTIONED LOOP IS PASSED OVER THE LATCH TO LIE ON THE SHANK OF THE COMPOUND NEEDLE, AND RETRACTING SAID COMPOUND NEEDLE WHEREBY SAID PILE LOOP IS SHED THEREFROM, AND ADVANCING SAID BASE FABRIC BY A FURTHER STEP. 